Papers by Author: F. Caliskan

Abstract: SiAlON ceramics were successfully produced in the form of powders from high purity kaolin, a hydrated aluminium silicate, Al2Si2O5(OH)4 type of clay mineral (comprises 83.85% kaolinite, 13.59% quartz, 0.88% feldspar, 1.37% others) of Canakkale-Can origin. Factors affecting SiAlON powder production were temperature, holding time, gas-flow rate and preparation methods. System optimisation was achieved following the results succeeded from numerous testing and characterisation (with XRD, SEM, EDS, BET, etc.) of each test. Changing in gas flow rate, temperature and holding time at plateau temperature had influences on the final powder yield, their morphologies and phase formation. The best conversion of kaolin clay mineral to SiAlON ceramic powder was the test run at 1475oC for 4 hour under 1 lt/min N2-flow. Product after the process was mainly of β'- Si3Al3O3N5 (z=3) powder along with small amounts of Al2O3, mullite and AlN phases. Some powder product exhibits furry type of wiskers morphology, which may be useful for using as a reinforcing material in particulate composite bodies.

Abstract: In this study, α-Si3N4 powder was produced by carbothermal reduction and nitridation (CRN) of quartz from Can-Canakkale. Carbon with a specific surface area of 110 m2g−1 and quartz powders were mixed then the powder mix was placed in an alumina tube furnace and reacted in between 1300-1500°C for 4 hours under nitrogen flow. The quartz powder was carbothermally reduced and nitrided to form silicon nitride powders. XRD results showed that the reaction product was mainly α-Si3N4 and contained some β-Si3N4 and residual quartz. In order to reduce amount of unreacted quartz, the raw materials mixture was grinded either with carbon black or with no carbon. After CRN reactions of separate grinded quartz powders with carbon, residual quartz was disappeared, reaction temperature was decreased and α-Si3N4 rate was increased. Hence, a better mixing of carbon and fine silica enhanced the α phase formation. SEM images and XRD pattern showed that sub micron particles (0.6–0.87m), high α-phase content Si3N4 powders can be produced at 1450°C for 4 h in flowing nitrogen gas during the CRN process.

Abstract: In this study, the production of β-Si6-zAlzOzN8-z (z =3) powders by the carbothermal reduction and nitridation of kaolin (Al2O3.2SiO2.2H2O) of Turkish origin (Can-Canakkale) was carried out with different processing parameters. It was found that the morphology of the produced SiAlON powder was mixture of irregular and whisker like grains. Therefore this morphology is suitable for liquid metal infiltration since the powders are already high porous. The kaolin powder containing stoichiometric rate carbon black and 30 % charcoal were pressed and reacted under nitrogen flow (2 lt/min) between 1400-1475°C for 4 h. After a carbothermal reduction and nitridation (CRN) process, porous β- SiAlON ceramic was produced from natural kaolin. Residual carbon and charcoal in the produced ß-SiAlON ceramic were fired at 1000°C giving extra porosity. The porous ß-SiAlON ceramics were sintered under N2 atmosphere at 1550°C for 2 h to make preform for infiltration process. SEM image analyses were carried out to determine preform and pore morphology and XRD analysis were performed for phase transformation.